Post sleeve positioning apparatus and method

ABSTRACT

A post sleeve installation device includes a standing structure, a structure coupled to the standing structure and configured to support a post sleeve below the standing structure, and a mechanism configured to enable selective translation of the support structure in three axes and rotation around a vertical axis. Locks are provided to lock the post sleeve at a selected position and orientation relative to the standing structure. A beam extending from one installation device to another measures or controls the relative spacing, orientation, and elevation of associated post sleeves, and related data is collected for off-site manufacture of fence panels. Additionally, a repository is provided, to which the data is transmitted for retention, and from which the data can be retrieved for manufacture of replacement fence panels.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/976,776, filed Dec. 22, 2010, now pending, which application is acontinuation of U.S. patent application Ser. No. 12/403,985, filed Mar.13, 2009, now issued as U.S. Pat. No. 7,861,434, where theseapplications are incorporated herein by reference in their entireties.

BACKGROUND OF THE INVENTION

1. Technical Field

The disclosed embodiments relate in general to systems for positioningfence posts in ground inserts, or post sleeves, that receive such posts,and in particular to systems for accurately and repeatably positioningpost sleeves relative to the surrounding terrain and/or adjacent postsleeves.

2. Description of the Related Art

Fences are ubiquitous in modern society, used in a vast range ofapplications, to mark and accent boundaries, provide security, andcontrol movement of people and animals. Thousands of miles of new andreplacement fences are installed every year in the U.S., and utilizevast amounts of construction related natural resources.

FIG. 1 shows a landscape with a fence 100 extending along portionsthereof. The fence 100 shown in FIG. 1 comprises two major segments, orruns 102. A run is a section or portion of a fence that extends betweennatural dividing points such as corners, gates, buildings, etc. Exceptwhere a fence is attached to a building, each run 102 generally has amain post 104 a at each end and line posts 104 spaced between the mainposts. Each pair of adjacent posts 104 has a fence panel 106 coupledbetween them. Each panel 106 comprises horizontal elements, or rails108, and vertical elements, or fence boards 110.

Typically, fence construction and installation involves a number ofsteps. In some cases, a site survey is done to determine the preciselocation of the fence and to prevent the all-too-common (and potentiallyvery expensive) occurrence of installing a fence a few inches or feetbeyond the actual property line. A contractor visits the site toestimate the materials and labor required to build and install thefence. In addition to simply measuring linear feet required, elementssuch as topography and obstructions must be reviewed and accounted for.If the fence location has not been marked by the owner or surveyor, thecontractor may mark the location during the initial visit, or during alater visit. Installation is scheduled, and materials are ordered anddelivered to the site.

Depending on the scope of the project, the locations and spacing of thefence posts may be determined and laid out in advance, by a landscapearchitect, for example, or left to the installation crew to determine onsite. In either case, the spacing of the posts is limited by thematerial available, and typically is selected to make best use of thatmaterial. For example, 96 inch lumber is commonly used to frame woodenfences, so the maximum distance between posts cannot exceed 96 inches.On the other hand, if the contractor uses 96 inch lumber, it would bewasteful to set the posts 60 inches apart, which would result in aboutthree feet of waste from every framing rail. However, because of otherconsiderations, some waste is unavoidable. It is generally preferable toevenly space the posts of a given run of fence, to provide an attractiveand unified appearance. Inasmuch as such a run will rarely be evenlydivisible by eight feet, each post will be something less than eightfeet apart. Additionally, if the terrain includes changes in elevationwhich the bottom and or top rail must follow, the length of the angledframing rails between two posts that are at different heights may bemuch greater than the lateral distance between the posts, which reducesthe maximum permissible horizontal distance between any of the posts ofthat run. Furthermore, it can be difficult, or at least time consuming,to precisely position a post to within a fraction of an inch, so amargin of an inch or two is generally provided. Thus, the posts may bespaced anywhere from a couple of inches to a couple of feet less thanthe maximum allowable distance. Finally, when building fences fromnatural materials such a wood, it is not uncommon for individual piecesto be unsuitable, because of, for example, a knot in a position thatunacceptably weakens a part, or an excessively warped board, etc. Forall of these reasons, some material waste is expected and allowed for inthe original estimate when calculating the materials for the framerails, and, for similar reasons, when calculating materials for fenceboards and posts.

Once the materials and crew are at the site, and with post locationsmarked, the post holes are dug, and the posts are installed. Each posthole may be partially backfilled with gravel to improve drainage, andthe post is then stood in the hole and held in place by several stakesdriven into the ground around the post and braces of scrap lumber nailedto the stakes and the sides of the post. A concrete footing is pouredinto the hole around the post and allowed to set, and the stakes arelater removed. With all the posts in place and the footings setsufficiently to remove the braces, frame rails are cut to fit, andattached to the posts, extending between adjacent posts along the bottomand top of the fence. Fence boards are then cut to length and attachedto the frame rails. Perfectly parallel and consistently spaced fenceboards along the entire fence run is important, because differences inspacing will become very obvious to an observer when there is daylightbehind the fence. Because of variations in the spacing of the posts, itis often necessary to rip fence boards lengthwise to maintain thecorrect spacing in some of the panels of a fence run. Additionally, thelengths of the fence boards may vary considerably. For example, theground line between posts can have obstructions or changes in elevationthat the installer adjusts for in the length of the fence boards inorder to maintain a straight line at the top of the fence while stillmaintaining proper spacing or ground clearance at the bottom.Additionally, many fences include decorative features along the top,such as arches or waves, in which case the builder may extend the fenceboards above the desired finish line, and cut the fence boards to followthe desired shape, after installation. The posts are also cut down tothe final length after installation, and post caps or finials are oftenattached to the tops. After the fence is installed, it is usuallypainted or stained to protect the wood and extend its useful life.

If properly executed using good quality material, a fence that is builtand installed as described above can be very attractive, and can lastfor many years. However, it will be noted that there is a significantamount of waste that is produced. Not only does such waste result inhigher material costs, it increases shipping costs because it must betransported to the site and later removed, it increases landfill use,and fees, and wastes otherwise valuable resources.

In view of the expense, labor, and waste associated with installing afence that is custom-built on site, another method of building andinstalling fences has been introduced. Pre-manufactured fence panels arebecoming more available, and increasingly can be found in a wide varietyof materials, including wood, vinyl, composite, aluminum, steel,concrete etc., and in a wide variety of designs.

Pre-manufactured panels or kits are typically sold from retail lumberand hardware outlets. The panels and kits are provided in standard sizesand are ready for installation. One common panel size, of the manyavailable, is six feet tall by eight feet long. The installer digs thepost holes at intervals of eight feet plus the width of a fence post,and places the first post, with stakes and braces to hold it plumb whilethe concrete sets, as described above. However, the installer alsoattaches the first fence panel to the post, and may attach the secondpost to the first panel at the same time, installing both poststogether. The installer then progresses post-by-post, attaching a panelbetween each pair of posts before pouring the footing around the secondof the pair, bracing each post and shimming up each panel to ensure thatthe post is held plumb and the fence level until the post footings aresufficiently hardened, which may be several days because of the mass ofthe fence being supported. This process ensures that the spacing betweenthe posts is correct for the eight-foot panels. At the end of a fencerun, if the last post is less than eight feet from the previous one, theinstaller cuts a fence panel to fit in the remaining space.Alternatively, the installer may install all of the posts first, butthis requires significant care to ensure that the distance between theposts is exactly correct. Otherwise, it may be necessary to trim thepanel to fit, or shim the post to fill a gap.

In contrast to site built fencing, pre-manufactured fence panels can beproduced efficiently, inexpensively, and at a consistent, predictablequality. Because they are produced in a manufacturing facility, wastecan be significantly reduced, and the waste that is produced is morelikely to be recycled either internally to produce other products orexternally rather than sent to a landfill. Material handling methods andautomated machines for material optimization allow utilization of alllengths of raw materials. The factory can obtain lumber that has notbeen cut to standard lengths, but is the full length of the log, orstem, from which it was milled. Scrap that won't work on one fence panelor design can be diverted and used for another. Flaws and defectivelumber can be detected automatically, and can often be cut out, allowingthe remaining material to be salvaged. This optimization anddefective-material/scrap management process is much more environmentallyfriendly than site-built fence processes, especially as it relates toreducing the production, and increasing the productive recycling, ofwaste lumber. As tree trunks don't come in perfect length increments,the factory can bring in material in lengths determined by the actualtree trunks and optimize those random lengths via computer to bestutilize the material, and minimize waste. The panels can be primed orfinished in spray booths or dip tanks in large volumes, using betterquality control, wasting less material, and reducing or eliminating theenvironmental impact that arises from on-site finishing.

Overall, fences built using pre-manufactured fence panels can be mademore efficiently, less expensively, and to higher and more consistentquality standards, with less waste and less environmental impact, thanfences custom-built on site.

Optimization systems are commonly used in the lumber industry at variousstages between the forest and the finished product, to maximize theyield of salable lumber from each stem. For example, in a sawmill, stemsare cut into boards of various thicknesses for curing. After curing, theboards are carried by automatic machinery through a series of scannersof various types, to detect defects such as knots, checks, bow, warp,wane, etc. The system determines where to cut the boards for the bestyield according to various criteria. For example, a rough board might bewide enough to cut a 2×12 board from, which, because of some minor knotsand wane, would be graded as 2-and-better. However, if cut differently,the same rough board might also yield one 2×6 board of select grade andone 2×4 board of economy grade. If the optimization system is programmedto select for the best financial yield, and if the programmed marketvalue of the 2×12, 2-and-better board is less than the combined marketvalue of the 2×6, select, and 2×4, economy boards, the optimizer systemwill automatically cut the rough board into the 2×6 and 2×4 boards,which results in more material waste, but more profitability for themill. On the other hand, if the system is programmed to select forgreatest material yield, the system will cut the rough board into the2×12 size.

Another criterion that is commonly used in the optimization process islength, because the dimensional retail lumber market heavily preferslengths that are 8 feet and longer, whereas the fence board marketprefers 5 and 6 foot long 1×6 nominal fence boards, with a heavypreference for the 6 foot lengths. Most retail outlets offer dimensionallumber, e.g., 2×4, 2×6, and 2×8, in 8, 10, and 12 foot lengths, but donot sell shorter lengths. Even with optimization, sawmills inevitablyproduce some lumber that is shorter or narrower than these desiredlengths or widths. With regards to fence boards, at present, there issome commercial market for 5 foot lengths, but almost none for shorterlengths. Because there is very little market for these “mill shorts,”they are typically scrapped or sold at very low cost.

Some manufacturers of pre-manufactured fence panels have begun toproduce fence designs that make greater use of mill shorts in order toexploit the relative abundance and low cost of the material. Forexample, the panels of the fence 100 of FIG. 1 are of a 6 foothorizontal lattice-top design sold by the Copper River Fence Co., inwhich most of the fence board material is cut from lengths that areshorter than 5 feet, which is shorter than the typical fence boardretail market can effectively stock and sell.

BRIEF SUMMARY

According to various embodiments, systems and methods related toproduction and installation of fences, fence posts, and post sleeves forsupporting fence posts are provided. According to an embodiment, aninstallation system is provided, comprising a standing structure havinga plurality of legs, a support structure coupled to the standingstructure and configured to support a post sleeve below the standingstructure, and a translation control mechanism configured to enableselective translation of the support structure along first and secondhorizontal axes, and a vertical axis, relative to the standingstructure. Additionally, a rotation mechanism is provided to permitorientation adjustment of the post sleeve, relative to the standingstructure. The standing structure is configured to be leveled so as tosupport the post sleeve in a vertically plumb position, and Lockingmechanisms are provided that can prevent translation of the supportstructure.

According to various embodiments, means are provided for controlling ormeasuring distance, angle and elevation of one post sleeve from another.According to an embodiment, data collection methods are provided forcollecting data from the installation system, and for transmitting thedata to a central repository, from which the data can be retrieved formanufacture of fence panels.

A manufacturing process is provided, according to an embodiment, formanufacturing made-to-order fence systems using mass-production methodsand optimizing processes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows a landscape with a fence.

FIG. 2 shows a post sleeve positioning system according to anembodiment, including a pair of post sleeve installation devices and aspacing beam.

FIG. 3 shows a plan view of elements of one of the post sleeveinstallation devices of FIG. 2, showing position control and lockmechanisms for x, y, and z axes and orientation.

FIG. 4 shows a perspective view of elements of the post sleeveinstallation device of FIG. 3, showing additional details of theposition control and lock mechanisms.

FIG. 5 shows an elevation view of z-axis and orientation control andlock mechanisms of a post sleeve installation device according to analternative embodiment.

FIG. 6 shows a post sleeve attachment mechanism and quick releasemechanism of the post sleeve installation device of FIG. 3.

FIG. 7 shows a column assembly according to an alternative embodiment.

FIG. 8 shows the spacing beam of the post sleeve positioning system ofFIG. 2.

FIG. 9 shows a detailed view of a coupling mechanism of the spacing beamof FIG. 2, as indicated in FIG. 2 at 9.

FIG. 10 shows a post sleeve positioning system according to anotherembodiment.

FIG. 11 shows a detail of the system of FIG. 10.

FIGS. 12 and 13 each show a post sleeve installation device according toa respective embodiment.

FIG. 14 shows a ground scanner system according to one embodiment.

DETAILED DESCRIPTION

The processes and embodiments that are described hereafter are to beunderstood as referring to examples that can be subject to aconsiderable degree of variation without departing from the scope of theinvention.

As noted above, pre-manufactured fence panels provide a number ofbenefits over conventional site-built fences. Nevertheless, they are notwidely used, especially by commercial fence builders. A fundamentalproblem that prevents wider adoption of pre-manufactured fence panels isthat they are not manufactured for specific locations, but are made tostandard sizes, so the user does not have the option of usingnon-standard post spacing. Because the spacing must conform to astandard, a short panel is almost always required at one of the ends ofa run, which can detract from the appearance of the finished fence andadd to the waste factor. Additionally, a typical pre-manufactured fencepanel can only be installed to extend perpendicular to a vertical post,so it cannot follow a change in elevation. The installer is obliged tostair-step the panels, as illustrated in the run 102 a of FIG. 1, ratherthan “racking” the rectangular shape to become a parallelogram roughlyfollowing the topography. Furthermore, stair stepping generally resultsin a gap under the fence at the low side of each panel, which mayrequire that some extension be added to the bottoms of the panels tofill the gaps. These options may not be acceptable to the end user.Finally, commercial installers generally find it more efficient toinstall all of the posts first, then install the fence boards. However,because of the difficulty in spacing and elevating the posts withsufficient accuracy for pre-manufactured panels, and the resulting extraexpense entailed in more careful spacing, or reworking a panel when thespacing is not correct, commercial fence contractors often avoidpre-manufactured fence panels.

The inventor has recognized that if a more reliable and efficientmechanism were available for accurately positioning fence posts duringinstallation, pre-manufactured fence panels would be more widelyacceptable. Additionally, if custom fence panels could be built in afactory setting, they would benefit from many of the same advantagesthat are associated with the pre-manufactured panels, which arecurrently available only in standard styles and sizes.

According to an embodiment, a system is provided for selectivelypositioning post sleeves in the ground, each sleeve being configured toreceive a respective fence post. Post sleeves are disclosed, forexample, in U.S. patent application Ser. No. 12/163,506, filed Jun. 27,2008, and entitled “Post Sleeve Assembly,” which application isincorporated herein by reference in its entirety. Post sleeves aredevices that are configured to be permanently fixed in the ground at thelocation of a fence or sign post, and into which the post is laterpositioned. Once a post sleeve is set in the ground, the preciseposition and depth of the post is fixed, and therefore the relativepositions and orientations of adjacent posts are also fixed, byrespective post sleeves, before the posts are emplaced. Accordingly, thedimensions of a fence panel that is to be installed between two adjacentposts can be determined, from the relative positions and orientation ofthe post sleeves, to a degree sufficient to manufacture the paneloffsite, with confidence that the panel will properly fit between theposts that are eventually placed in the sleeves. Finally, if theposition and orientation of the post sleeves of a fence can beadequately controlled during installation, the dimensions of each of thefence panels can be planned in advance, so that the posts and fencepanels can be ready for installation when the post sleeves areinstalled.

FIG. 2 shows a post sleeve positioning system 200 according to oneembodiment. The system 200 includes a plurality of post installationdevices, or “spider frames” 202 a, 202 b, and a spacing beam 204 havingfirst and second ends 205, 207. Hereafter, except where it is necessaryto distinguish between spider frames 202 a and 202 b of FIG. 2, theywill be referred to simply by reference number 202.

Each spider frame 202 is configured to suspend a post sleeve 206 in apost hole in a position that is minutely adjustable in three axes andaround a longitudinal axis. The spacing beam 204, when coupled to extendbetween two spider frames 202 supporting respective post sleeves, isconfigured to determine or control the relative positions andorientations of the post sleeves 206.

Using at least two spider frames 202 and a spacing beam 204, a user caninstall post sleeves in preselected positions, relative to each other,well within acceptable tolerances for installation of pre-manufacturedfence panels. By leapfrogging two or more spider frames 202, as will bedescribed later in more detail, a user can similarly install any numberof post sleeves.

Each spider frame 202 comprises a leg assembly 208, a column assembly210, and a position assembly 212. The leg assembly 208 supports thespider frame 202 and includes a plurality of legs 214 with adjustablefeet 216 by which the spider frame 202 can be positioned exactly levelover a post hole, regardless of the terrain. According to an embodiment,as shown on the spider frame 202 a, the legs 214 each include an innertelescoping sleeve 215 to accommodate extreme slopes. Spirit vials 218are attached to an upper surface of the leg assembly 208 to facilitateleveling. Adjustment knobs 220 at the top of each leg 214 are coupled toan extension mechanism of the respective leg. Using a standard cordlessdrill with a driver insert, the user can engage a socket provided ineach knob 220 to adjust the length of the respective leg 214. Rotationof the knob 220 in one direction, e.g., clockwise, extends therespective foot 216 and lengthens the leg, while rotation of the knob inthe opposite direction retracts the foot 216 and shortens the leg. Theknobs can also be manually rotated. According to an alternateembodiments, motors or actuators are provided in the spider frame tocontrol the leg lengths. Handles 221, shown on spider frame 202, areprovided to simplify moving and lifting of the spider frame. Accordingto an embodiment, at least two of the legs 214 are provided withlockable wheels to permit a single installer to move the spider frame“wheelbarrow” style.

Turning now to FIG. 3, the column assembly 210 and portions of theposition assembly 212 are shown. The position assembly 212 includes acolumn assembly bearing block 232 with a cylindrical aperture 234extending therethrough parallel to the Z axis and two guide channels 235extending parallel to the X axis. A pair of guide shafts 236 arepositioned in respective ones of the guide channels 235 with a pair of Yaxis racks 240 extending between the guide shafts at respective ends.The column assembly 210 is supported by the bearing block 232, which inturn is coupled to the leg assembly 208 via the guide shafts 236. Theends of guide shafts 236 engage respective Y-axis bushings 250 that arepositioned in slots formed in the leg assembly 208, permitting the guideshafts 236, with the bearing block 232 and column assembly 210, totranslate in the Y axis. A Y-axis lock 252 is coupled to the legassembly 208 and includes a rack engagement block 254 configured toengage the teeth of one of the Y-axis racks 240, in order to lock theguide shafts 236 in the Y axis. A pneumatic piston 256 is configured todisengage the Y-axis lock 252 when activated. The position assembly 212also includes mechanism for locking the position of the column assemblyin the X and Z axes and orientation. These mechanisms will be shown anddescribed in more detail later.

The column assembly 210 comprises a Z-axis index 222, a Z-axis spacer226, and a post sleeve support assembly 228, which is described indetail with reference to FIG. 7. The Z-axis index 222 has four verticalfaces 229, each of which is provided with a pair of longitudinal slots225 and an elevation scale 223 between the slots. Adjustable supportsaddles 227 slidably engage the longitudinal slots 225, and areconfigured to receive an end of the spacing beam 204, which will bedescribed later. The Z-axis index 222 is rigidly coupled to one end ofthe Z-axis spacer 226, while the sleeve support assembly 228 is rigidlycoupled to the other end of the Z-axis spacer. Thus, the distance andorientation of the post sleeve support assembly 228 remains fixed withrespect to the Z-axis index 222. The Z-axis spacer 226 extends throughthe aperture 234 of the column assembly bearing block 232 so that aportion of the column assembly is above the bearing block and a portionis below. The Z-axis spacer 226 is translatable in the Z axis androtatable around a longitudinal axis that lies parallel to the Z axis,within the aperture 234 of the column assembly bearing block 232. AZ-axis control 268 is provided (see FIG. 5) that locks the columnassembly 210 in the Z-axis and in orientation, relative to the bearingblock 232.

Turning to FIGS. 4 and 5, elements of the position assembly aredescribed in more detail. FIG. 4 shows the position assembly 212 in planview, with outlines of the leg assembly 208 and the column assemblybearing block 232 provided in dashed lines to show relative positions.Also shown are the locations of slots 251 in which the Y-axis bushings250 are positioned to permit translation of the bearing block 232 andcolumn assembly 210 in the Y axis. The spacer 226 is positioned in thecylindrical aperture 234, and includes a longitudinal aperture 231through which a portion of the Z-axis control 268 extends.

The bearing block 232, with the column assembly 210, slides along theguide shafts 236 in the X axis. X-axis bushings 258 are provided in theguide apertures 235 to facilitate movement of the bearing block 232along the guide shafts 236 without undue play. An X axis rack 237 iscoupled to one of the guide shafts. An X-axis lock 260 is coupled to thebearing block 232 and comprises a rack engagement block 262 configuredto engage the teeth of the X-axis rack 237, in order to lock the bearingblock 232 in the Y axis. A pneumatic piston 264 is configured todisengage the X-axis lock 260 when activated.

FIG. 5 shows, in perspective view, the position assembly 212 andportions of the column assembly 210. The bearing block 232 and thespacer 226 are shown in dashed lines for reference. The Z-axis control268 includes a Z-axis lift bracket 380, a lead screw 382, and a Z-axisdrive. The Z-axis lift bracket 380 is coupled to the bearing block 232and cantilevers into the longitudinal aperture 231 of the spacer 226,which extends for a substantial portion of the length of the spacer. Theshape of the Z-axis lift bracket 380 and the width of the longitudinalaperture 231 cooperate to permit rotational adjustment of the columnassembly 210 across a significant range. For example, in the embodimentpictured, the column assembly 210 can be rotated about 20-25 degrees ineither direction from center. Provided the installer is able to orientthe spider frame 202 to within about 20 degrees of the correctorientation, the column assembly 210 can be precisely adjusted to thedesired orientation. The lead screw 382 is coupled to a plate at thebottom of the spacer 226 and extends axially within the spacer andthrough an aperture 386 in the Z-axis lift bracket 380. The Z-axis driveis mounted to the Z-axis lift bracket 380 and engages the lead screw382. Although not shown in detail, the Z-axis drive operates in a mannersimilar to the worm drive 330 described with reference to FIG. 8. Adrive input shaft 384 is provided for operation of the Z-axis drive,which, moves the column assembly in the Z axis, relative to the bearingblock 232. The drive input shaft 384 is provided with a socket that isconfigured to receive a drive key, and can be operated using a commoncordless drill.

An orientation lock 390 is coupled to the Z-axis lift bracket 380 insidethe spacer 226, and includes a brake shoe 392, pivotably coupled to thelift bracket, and a pneumatic actuator 394 that is rigidly coupled tothe lift bracket via an actuator mount that is not shown. A spring pullsthe brake shoe 392 down into engagement with the inner surface of thespacer 226, effectively locking rotation of the column assembly 210.When the actuator 394 is activated, it pushes upward on the brake shoe392 to disengage it from the spacer and permit rotational and Z-axisadjustment of the column assembly 210.

FIG. 6 shows the lower end of the Z-axis spacer 226 and the post sleevesupport assembly 228. The support assembly 228 includes an exteriorcasing 290, shown partially cut away to show details of a sleeve liftlock 292. The support assembly is also shown separated from the lowerend of the spacer 226 to better illustrate a quick release mechanism300, by which the support assembly can be easily coupled and decoupledwith the spacer 226 allowing attachment of other devices such as boltpattern plates or removable post hole molds. The lift lock 292 includesa pair of lift latches 296 configured to engage respective notches oninner surfaces of a post sleeve via slots 298 in the casing 290, inorder to couple the sleeve to the support assembly 228. A pneumaticcylinder 295 is configured to withdraw the latches into the casing torelease the post sleeve. A manual release 297 is also provided,comprising a section of braided wire coupled to the lift lock andextending to a pull-ring outside the upper end of the support assembly228.

The quick release mechanism 300 is provided to couple the post sleevesupport assembly 228 to the Z-axis spacer 226. The quick releasemechanism 300 includes a pair of support bars 302 coupled to the upperportion of the post sleeve support assembly 228, and engagement notches304, a spring latch 306, and a release handle 308 coupled to the lowerend of the Z-axis spacer 226. To couple the post sleeve support assembly228 to the Z-axis spacer 226, the user first positions one of thesupport bars 302 in the engagement notches 304, then applies upwardforce to the post sleeve support assembly until the spring latch 306engages the other of the support bars 302. To release the supportassembly 228, the user presses the release handle 308, which disengagesthe spring latch 306 from its support bar 302, permitting the othersupport bar to disengage from the engagement notches 304.

For operation of the various pneumatic devices described above, thespider frame 202 can be provided with an onboard source of pressurizedair, as described later in an alternate embodiment, or can include apneumatic connector configured to receive pressurized air from anexternal source, such as from a compressor, storage tank, etc.

In operation, a user first attaches a post sleeve to the spider frame202. This can be done by engaging the post sleeve support assembly 228in a post sleeve, then coupling the quick-release mechanism 300, withthe spider frame standing on buckets or saw horses, or otherwisesomewhat elevated to provide sufficient clearance. The user, preferablywith a helper, then positions the spider frame 202 over a previouslyprepared post hole. The user adjusts the legs 214 until the spider frame202 is level and stable, referring to the spirit vials 218 to find thelevel position. The user then releases the Y-axis lock 252 by applyingair pressure to the pneumatic piston 256, and moves the column assembly210 in the Y axis until it is correctly positioned, then releases theair pressure from the piston 256, which locks movement in the Y axis.The user then releases the X-axis lock 260 by applying air pressure tothe pneumatic piston 264, and moves the column assembly 210 in the Xaxis until it is correctly positioned, then releases the air pressurefrom the piston 264, which locks movement in the X axis. Alternatively,the user can release both X- and Y-axis locks simultaneously and movethe column assembly freely in both axes, then, when the assembly isproperly position, engage both locks again.

Having positioned the post sleeve in the X and Y axes, the user thenactivates the pneumatic actuator 394 to free the rotation lock 390 andthe Z-axis control 268. Operation of the Z-axis drive moves the columnassembly, with the post sleeve attached, in the Z-axis, and orientationcan be is simultaneously adjusted. When the actuator 394 is released,the brake shoe 392 again engages the spacer 226, rotationally lockingthe column assembly.

With the post sleeve correctly positioned, the user back-fills the posthole with concrete around the post sleeve. When the concrete has setsufficiently to hold the post sleeve in position, the user releases thelift lock 292 to separate the post sleeve support assembly 228 from thesleeve, and raises the column assembly 210 until the post sleeve supportassembly 228 is out of the sleeve. The user can then move the spiderframe from its position over the post hole, and repeat the installationsteps to install additional sleeves.

In alternate embodiments, the sleeve can be placed in the hole first,then the spider frame placed over the hole and the sleeve engaged whilein the hole. In the event there is no “partner” to assist, this is adesired method, due to the weight concerns.

FIG. 7 shows a column assembly 400 according to an alternate embodiment,including a Z-axis position assembly 224 and a rotation lock 278. Thecolumn assembly 400 is shown with the outer portion of the Z-axis indexremoved to show details of the Z-axis position assembly 224. The Z-axisindex includes a pair of guide tracks extending longitudinally alongopposite corners, and in other respects is substantially identical tothe Z-axis index 222 described above. The outline of the column assemblybearing block 232 is provided in dashed lines to show details andposition. In addition to the Z-axis position assembly 224 and rotationlock 278, the column assembly 400 comprises a Z-axis tensioner 284, apneumatic supply and control assembly 285, and the post sleeve supportassembly 228.

The Z-axis position assembly 224 includes a pair of Z-position controllegs 241 that each has a wheel 242 at a bottom end and a guide rail 244that engages a respective one of the guide tracks of the Z-axis index.The engagement of the guide rails 244 with the guide tracks allows theZ-axis index to slide along the guide tracks in the Z axis. A Z-axislock 268 is provided that locks the Z position control legs 241 relativeto the Z-axis index. When the Z-axis lock is engaged, the Z positioncontrol legs 241, including the wheels 242 bearing on the upper surfaceof the column assembly bearing block 232, support and control theposition of the column assembly in the Z axis, while permitting freerotation of the column assembly.

The Z-axis position assembly 224 comprises a Z-axis rack 266 coupled toone of the Z position control legs 241 and a Z-axis lock 268 coupled tothe Z-axis index. The Z-axis lock 268 includes a rack engagement block270 configured to engage the teeth of the Z-axis rack 266 in order tolock the column assembly 400 in the Z axis. A pneumatic piston 272 isconfigured to disengage the Z-axis lock 268 when activated.

The rotation lock 278 is coupled to the column assembly bearing block232, and comprises a spacer sleeve 276 positioned in a cavity inside thebearing block 232, a locking band 280 that extends around thecircumference of the spacer sleeve 276, and a pneumatic piston 282configured to disengage the rotation lock 278 when activated. The spacersleeve 276 includes an aperture 277 extending therethrough, aligned withand coaxial to the aperture 234 of the bearing block 232. A key isprovided in the aperture of the spacer sleeve 276, extending parallel tothe Z axis. A keyway 274 extends longitudinally in the Z-axis spacer226, which is engaged by the key of the spacer sleeve 276. The key andkeyway 274 are respectively sized to permit the key to slide easily inthe keyway, so that the sleeve is rotationally fixed with the spacer,but the spacer is able to move parallel to the Z axis, with the keysliding in the keyway. The locking band 280 is normally biased toward alocked position, in which it tightly grips the spacer sleeve 276 to lockthe spacer sleeve rotationally. The pneumatic piston 282 is configuredto separate the ends of the locking band 280 when activated, whichpermits the spacer sleeve 276 to rotate with respect to the bearingblock 232. Because the spacer sleeve 276 is rotationally fixed withrespect to the Z-axis spacer 226 by means of the key and keyway 274, thelocking band 280, when engaged, prevents rotation of the Z-axis spacer226, together with the other components of the column assembly, whilethe column assembly remains free to move in the Z axis.

The pneumatic supply and control assembly 285 includes an air canister287 to supply pressurized air for the various pneumatic pistons of thespider frame 202. The valves and plumbing of the air circuit areprovided in accordance with conventional principles, which are wellknown in the art and so are not shown or described in detail.

The Z-axis tensioner 284 is coupled to an upper portion of the columnassembly 400 and comprises a braided wire 286 coupled at one end to theZ-axis index, with the other end wound onto a spring loaded spool 288.The tensioner 284 applies a positive Z-axis bias to the Z-axis index tooffset a portion of the weight of a post sleeve attached to the postsleeve support assembly 228 to assist the user in adjusting the Z-axisposition. The spring tension of the tensioner 284 is adjustable so thatit can be set to accommodate the weight of the post sleeve, which may bemade from a number of materials, including light weight plastic and highdensity concrete, as described in more detail in previously referencedU.S. patent application Ser. No. 12/163,506.

In operation, with the leg assembly 208 positioned and leveled, the userreleases the Z-axis lock 268 by applying air pressure to the pneumaticpiston 272, and raises or lowers the Z-axis index, with the guide rails244 of the Z position control legs 241 sliding in the guide tracks 238of the Z-axis index so that the wheels 242 remain in contact with theupper surface of the bearing block 232. When the vertically mobileportion of the column assembly 400, which includes the Z-axis index, theZ-axis spacer 226, and the post sleeve support assembly 228, iscorrectly positioned, the user releases the air pressure from the piston272, locking the column assembly in the Z axis. The user then releasesthe rotation lock 278 by applying air pressure to the pneumatic piston282, and rotates the column assembly 400 around the Z axis. With thecolumn assembly 400 locked in the Z axis, the wheels 242 of theZ-position control legs roll on the surface of the bearing block 232 topermit rotation of the column assembly while holding it fixed in the Zaxis. When the column assembly 400 is correctly oriented, the userreleases the air pressure from the piston 272 to rotationally lock theassembly. As mentioned above with respect to the X and Y axis positions,it is not essential that each position be established sequentially. Auser can release all of the position locks, and move the column assemblyrotationally and in all three axes simultaneously, to arrive at adesired position and orientation.

While various mechanisms have been disclosed as being actuated bypneumatic pistons that are configured to disengage their respectivelocking mechanisms or provide z axis control, according to alternativeembodiments, other control and locking systems are provided. In oneembodiment, manually operated locks are provided, such that the userengages and disengages the locks by rotating respective levers orlatches. In another embodiment, a desired position is automatically ormanually entered into a control circuit, sensors provided at variouslocations detect the position and orientation of the column assembly,and servomotors are controlled to reposition the column assembly to thedesired position and orientation. According to an embodiment, the spiderframe is self leveling. Sensors such as are well known in the art detectthe degree of correction required to level the frame, and activateservomotors, pistons, or the like, to extend or retract the feet asnecessary.

Turning now to FIG. 8, the spacing beam 204 is shown according to anembodiment, with portions cut away to show internal detail. The spacingbeam 204 includes a hollow casing 310, an extension arm 312, anextension mechanism, 314, a fixed arm 316, and first and second mountingfixtures 318. The hollow casing 310, the extension arm 312, and thefixed arm 316 are formed from materials that are selected to besubstantially rigid and lightweight, such as, for example, aluminumextrusion, fiberglass, carbon fiber, structural foam, etc. The hollowcasing 310 includes a handle section 320 that incorporates electroniccontrol circuitry, the operation of which will be described later. Theextension arm 312 is configured to slide telescopically within thehollow casing 310. The first mounting fixture 318 is coupled to a firstend 336 of the extension arm 312, which also corresponds to the firstend 205 of the spacing beam. A drive nut 322 coupled to a second end 338of the extension arm 312, inside the casing 310. Scale markings 324along the top of the extension arm 312 indicate, at the point where theextension arm enters a first end 341 the hollow casing 310, a totallength of the spacing beam 204.

The extension mechanism 314 includes a mounting plate 326, a worm drive330, and a threaded drive rod 328 coupled to the mounting plate via abearing block 344, and having a worm gear of the worm drive fixedthereto. A drive input shaft 332 is coupled to a worm of the worm drive330, which engages the worm gear for rotation of the drive rod 328. Anencoder 334 is mounted on the mounting plate and coupled to an end ofthe drive rod 332 to detect and meter rotation of the drive rod relativeto the casing 310. The mounting plate 326 is rigidly coupled to thecasing 310, with the drive rod extending longitudinally within thecasing and the drive input 332 extending from the casing via anaperture. The drive rod 328 engages the drive nut 322 of the extensionarm 324 inside the casing 310 such that rotation of the drive rodextends or retracts the extension arm, according to the direction ofrotation. The drive input shaft 332 is provided with a socket that isconfigured to receive a drive key, and can be operated using a commoncordless drill. According to alternate embodiments, a servo motor isprovided, configured to rotate the threaded drive rod 328, the drive nut322, or the drive input 332 to extend and retract the extension arm 324.

The fixed arm 316 is rigidly coupled to the hollow casing 310 andextends a short distance from a second end 342 of the casing. The secondmounting fixture 318 is coupled to the portion of the fixed arm 316 thatextends from the casing 310, at the second end 307 of the spacing beam204.

In the embodiment shown, the first and second mounting fixtures 318 aresubstantially identical, and one is shown partially exploded in FIG. 8.Each mounting fixture 318 includes a hinge knuckle 350 that is rigidlycoupled to one of the fixed or extension arms 316, 312. The hingeknuckle 350 is rotatably coupled to a mounting bracket 354 by a couplingpin 352. An encoder is mounted in the hinge knuckle 350 and coupled tothe coupling pin 352 to detect and meter rotation of the hinge knuckle350 relative to the mounting bracket 354. The mounting brackets 354 alsoinclude a scale 358 indicating degrees of rotation, and an indexingpointer 356 is provided on the end of the respective arm 316, 312,positioned to indicate on the scale 358 the angle of the beam 204relative to the mounting bracket 354. Spirit vials 360 are provided onthe fixed and extension arms 316, 312 and configured to be centered whenthe beam 204 is in a level position. The mounting brackets 354 areconfigured to be coupled to an index face 229 of the column assembly 210of the respective spider frame 202, as described in detail withreference to FIG. 9.

In embodiments that include electronic systems, a metering circuit isprovided in the handle section 320, and coupled to the encoder 334 ofthe extension mechanism 314 and the encoders 362 of the first and secondmounting fixtures 318, 319. The metering circuit is configured todetermine, from the signal provided by the encoder 334 the position ofthe extension arm 324 relative to the casing 310, and thus the overalllength of the spacing beam 204. From signals provided by the encoders362, the metering circuit determines the angle of each of the mountingbrackets 318, 319 relative to a longitudinal axis of the spacing beam204. The electronic system can also include an electronic level with adigital readout indicating the angle of the beam, and can provide anaudible signal when the beam is level, which relieves the installer ofthe necessity to refer to a spirit vial while adjusting the beam.

When the spacing beam 204 is level and coupled to extend between twospider frames 202, as shown in FIG. 2, the precise distance between thetwo spider frames is equal to the length of the beam, which is indicatedby the scale 324 on the extension arm 312, the relative orientations ofthe column assemblies 210 of the respective spider frames is reflectedby the angles of the mounting brackets 354 relative to the axis of thebeam, and the difference in elevation is obtained by reference to theelevation scales 223 on the index faces 229 to which the respectivemounting brackets 358 are coupled, as discussed below.

Turning now to FIG. 9, a detail of FIG. 2 is shown, indicated in FIG. 2by dashed circle 9. FIG. 9 shows the second end 207 of the spacing beam204, including the fixed arm 316 and the second mounting fixture 318,with the mounting bracket 354 coupled to a saddle 227, which in turn isslidably engaged to the longitudinal slots 225 of one of the faces 229of the Z-axis index 222. A second saddle 227 is shown in exploded view,coupled to an adjacent face 229. The saddle 227 includes a locking plate345 that is captured between facing pairs of the longitudinal slots 225so as to be slidable along the face of the index 222, but not removable.The locking plate 345 has a threaded aperture 347 that is engaged by atensioning knob 349. The tensioning knob 349 includes a threadedconnector 351 that traverses an aperture 353 in the saddle 227 andengages the threaded aperture 347 in the locking 347 plate 345. Whilethe tensioning knob 349 is loose, the locking plate 345 can slide alongthe longitudinal slots 225, but when the user tightens the tensioningknob 349, the saddle 227 and locking plate 345 cooperate to lock thesaddle in position.

A locking pin 370 of the mounting bracket 354 engages a transverseaperture 355 in the saddle 227 and corresponding apertures in themounting bracket 354 to form a hinged coupling between the mountingbracket and the saddle, which permits one end of the spacing beam 204 tobe coupled to a spider frame 202 as the user raises the other end untilthe spacing beam is level. The elevation of the mounting bracket 354 onthe index 222 can be read from the scale 223 adjacent to the top surfaceof the mounting bracket.

It will be recognized that the value indicated on scale 223 has norelation to the elevation of the mounting bracket relative to thebearing block 232 or the leg assembly 208, or even, directly, to theground on which the spider frame 202 is positioned. Instead, the valueis directly related to the distance of the mounting bracket from thepost sleeve coupled to the column assembly 210. Thus, the difference invalues indicated at the first and second mounting brackets 354 of thespacing beam 204, coupled to respective spider frames 202, representsthe difference in elevation between the respective post sleeves. If themounting bracket 324 that is coupled to the higher of the two spiderframes is aligned with the zero position at the bottom of thecorresponding scale 223, the value indicated at the opposite mountingbracket will be the actual difference in elevation between the postsleeves. Otherwise, it is a simple matter of subtraction to obtain thecorrect value.

According to an embodiment, the hinge knuckle 350 of the mountingfixture 318 is provided with an additional encoder that is configured toread the scale 223 of the Z-axis index 222 and provide a signalcorresponding to the vertical position of the mounting bracket 319 onthe index, and the metering circuit is configured to derive a relativeelevation difference of the post sleeves on the basis of signals fromencoders at the first and second ends 205, 207 of the spacing beam, toestablish the relative elevation difference.

According to another embodiment, laser distance finders are coupled tothe ends of the spacing beam 204 in proximity to the coupling pin 352,and configured to provide a signal corresponding to a distance from themounting bracket to a plate at the base of the Z-axis index, from whichthe elevation difference can be derived.

Installation of a number of post sleeves, for a fence run, for example,will now be described with reference to FIG. 2. To differentiate betweenthe elements of the spider frames 202 a and 202 b in the description,references to elements of the spider frame 202 a will include thecharacter “a,” while references to elements of the spider frame 202 bwill include the character “b.”

The basic layout of the fence is first established. This generallyinvolves determining the location of the main posts, and the appropriatespacing between the line posts. A fence line is then established. Thisis traditionally done by running a string line parallel to the fenceline some short specific distance away, which permits the installer tobuild the fence without interfering with the line, but having the lineavailable for reference. It is becoming more common for a contractor touse a laser plane projector, such as are used in many of theconstruction trades, to project a vertical plane along the fence line.The installer starts at the far end and works toward the projector,using the vertical line projected by the device to align the fence.

To install a number of post sleeves, an installer user first providespost holes at the general locations where the post sleeves are to beinstalled. A first post sleeve 206 is positioned in the X, Y, and Z axesusing a first spider frame 202 a, substantially as described above. Thespider frame 202 a is locked in orientation and all axes, oriented andaligned with the centerline of the fence line. The footing of the firstpost sleeve is then poured.

A second spider frame 202 b is positioned over the adjacent post holewith a second post sleeve attached. The second spider frame 202 b isleveled and the second post sleeve is correctly positioned in the Zaxis. The second spider frame 202 b is locked in the z axis only, beingotherwise free to move and rotate. Evaluating the two post sleeves, theinstaller determines which is at a higher elevation, which, in FIG. 2,is the sleeve of spider frame 202 b. Using support saddles 227 on themost nearly mutually facing faces 229 of the Z-axis indexes 222 a and222 b, the installer sets the higher sleeve's saddle 229 b to the zeroposition, and sets the opposing saddle 229 a to approximately or exactlythe same elevation. This can be done with a laser level or vial level,etc. The spacing beam 204 is then set to the desired length, and itsfirst end 205 is coupled to the saddle 227 a of the first spider frame202 a. With the X and Y axes and rotation of the second spider frame 202b unlocked, the second spider frame 202 b is manipulated until thesecond end of the spacing beam can be coupled to the saddle 227 b. Thelevel of the beam 204 is adjusted, if necessary, by moving the mountingbracket of the lower (202 a) of the spider frames until the beam isperfectly level.

The second spider frame 202 b is then brought into proper alignmentwith, and centered on the fence line, with the column assembly 210 bfloating in the X and Y axes and rotation, to permit alignment and anyfinal adjustments of the beam length. With the spacing beam 204 set andlevel, and the column assembly 210 b correctly positioned in the X and Yaxes and in orientation, the installer engages the respective locks,then pours the footing of the second post sleeve.

If the post sleeves are being installed to a prepared plan that setsforth specific values, the values will have been confirmed before andafter the footing is poured, and are thus known. If the sleeves arebeing installed according to a more general plan, in which, for example,the distances between fence posts have been substantially predetermined,but other parameters are to be established on site, data from the spiderframes and spacing beam is collected immediately after the footing ispoured, including distance, relative orientation, and relativeelevation.

One of the advantages provided by many of the disclosed embodiments isthat post sleeves can be installed according to very precise positionand orientation requirements. This is necessary when using fence panelsthat are manufactured before the sleeves are installed, because the sizeand shape of the panels are already fixed. However, another advantage isthat, where the fence panels will be manufactured after sleeveinstallation, sleeves can be installed with a certain degree oflatitude, because, however inexact the installation may be, the exactvalues of the relative positions and orientations of the sleeves areobtained once the sleeves are emplaced. This permits an installer towork much more quickly than would be possible when installing to veryprecise values, while still being able to obtain accurate values for themanufacturer of the panels.

Each post sleeve is provided with a unique identifier (UI). This can bea factory-installed serial number, a reference marking placed on thepost sleeve or on the footing as the sleeve is installed, some referencemarking on a plat map, GPS coordinates, etc. In any case, theseidentifiers are recorded with the collected data so that the correctfence panel can be manufactured and installed.

Once the data has been collected, the user decouples the spacing beam204 from the first and second spider frames and repeats the process bypositioning a third post sleeve coupled to a third spider frame in ahole prepared adjacent to the second post sleeve, with the second spiderframe now fixed in position and the third spider frame being adjustedaccordingly.

An installer may work with as few as three or four spider frames, whileall but the shortest fences will have many more posts to be installed.Accordingly, once the available spider frames have been used, the usertests the oldest of the footings for firmness of the concrete, and whensafe, moves that spider frame to the newest hole. Depending on how fastthe concrete sets and how fast the installer works, it may be necessaryto use three to six spider frames to efficiently install any number ofpost sleeves, leapfrogging each from the back of the line to the frontas the concrete in each hole sets.

As each post sleeve is positioned, data necessary to manufacture a fencepanel for that location is collected from the spacer beam 204, includingthe exact distance between the post sleeves, the relative orientation ofthe post sleeves, and the relative elevation of the post sleeves.

The data can be collected in a number of different ways. For example,the installer can merely read the values from the spacing beam 204 andZ-axis index, and write them down or enter them into a recording device.Alternatively, the spacing beam 204 can be provided with a meteringdevice that includes a transmitter, configured to transmit the relevantdata to a receiver that saves the data for each panel. Postidentification data can also be collected automatically or manually.According to various embodiments, each post sleeve is provided with aunique bar code identifier or RFID tag that the user scans to enter.

The user sends the data for the fence to a central data repositoryand/or a manufacturer, who then manufactures all of the panels, markseach panel with the appropriate information to identify the post sleevessupporting the posts between which it will be attached, and ships thepanels back to the user. The manufacturer may also cut posts to thecorrect lengths and ship those, as well. The user then correlates themarkings on the posts and panels to the UI of the post sleeves, and thenplaces the fence posts in the corresponding post sleeves and installseach fence panel between the designated pair of posts.

According to an embodiment, as the data is collected, it is immediatelyuploaded to the repository or manufacturer via a cellular or webconnection, allowing production of the panels to begin as the sleevesare being installed.

According to another embodiment, the positions and spacing of the fenceposts are determined in advance, and the fence panels are preordered. Inthis case, the user installs the post sleeves from a specific plan, andpositions the posts precisely as required to receive the panels. In sucha case, it becomes necessary to perform at least a basic survey of theproperty to establish overall dimensions and elevations. In a similarway, a user can install mass-produced fence panels at their standardspacing.

FIG. 10 shows a post sleeve installation system 420 according to anotherembodiment. Spider frames 422 are provided, that in most respects aresimilar to the spider frames 202 described previously, and areconfigured to permit adjustment of the position and orientation of apost sleeve as previously described. However, the spider frame 422includes a first prism 424 coupled at the top of its column assembly 428and axially aligned therewith. Accordingly, when the spider frame 422 iscorrectly leveled, the first prism 424 is centered directly above thepost sleeve 206. A second prism 426 is coupled to the column assembly428 at the end of a cantilevered arm 425 having a known length. A moredetailed view of the top of the column assembly 448 is shown in FIG. 11.The first and second prisms 424, 426 are configured to reflect a lightbeam back along a reciprocal vector. Thus, when a light, such as alaser, is projected at one of the prisms, it will be reflected directlyback to the source.

A surveyor device 428 is provided, which is configured to detect thepositions of the prisms 424, 426, and is capable of accuratelydetermining the angle and distance of each prism relative to theposition of the surveyor device. Devices employing such technologyinclude the “total station,” which is used in many industries forsurveying, rangefinding, and other tasks related to determining spatialrelationships of different elements. Total stations are produced by anumber of manufacturers, including, for example, Topcon South Asia PTELTD.

According to an embodiment, the surveyor device 428 is positioned in acentral location relative to a fence line to be installed. As the spiderframes are positioned at each post sleeve location, the surveyor derivesthe position of the sleeve from the position of the first prism 424, andthe orientation from the position of the second prism relative to thefirst. Given the exact positions and orientations of two post sleevesrelative to the position of the surveyor device 428, the device isprogrammed to calculate their positions and orientations relative toeach other, and to store or transmit that data. Where the installer isworking according to a pre-established plan, the parameters areprogrammed into the surveyor 428, which is configured to provide visualor audible signals to aid the installer in correctly and preciselypositioning each post sleeve 206.

Also illustrated in FIG. 10 is an installation method according to oneembodiment. Each hole 432 is only partially back-filled initially, usinga fast-setting concrete, expansion foam, or other formulation 430 sothat the spider frames can be moved more quickly. The user later returnsand finishes back-filling the holes with a concrete formulation 434 thatis selected for strength and weatherability. The first partial footing430 is configured to set very quickly, with sufficient strength to holdthe post sleeve 206, to permit the installer to work more quickly usingfewer spider frames.

Additionally, the material of the partial footing can be configured tohave a selected porosity, to permit water that enters the sleeve topercolate from the sleeve into the ground at a controlled rate.

FIG. 12 shows a spider frame 440 according to another embodiment. Thespider frame 440 is provided with a GPS receiver 442 that is configuredto collect position and orientation data from satellite transmissions.The data is collected by a collection device configured to derive andstore the values necessary to produce required fence panels.

Post positioning systems have been disclosed, according to variousembodiments, that employ spider frames with adjustable legs forpositioning post sleeves. However, the scope of the invention is notlimited to such structures. For example, according to an embodiment, amotorized system is provided that is self propelling, using wheels, ortracks similar to those of a bulldozer, and that includes a post sleeveattachment, as well as systems for manually or automaticallypositioning, orienting, and plumbing a post sleeve. The system can beconfigured to be operated by direct or remote control of an operator, orto be preprogrammed so as to move automatically from one position to thenext, guided by GPS, or by reference to a fixed position, such as atransmitter or a surveyor device, or by other known systems or methods.FIG. 13 shows, according to another embodiment, a cutaway view of a postsleeve 206 with a post sleeve positioning device 450 positioned in thecavity 462 of the post sleeve. The device 450 includes a weight 452, alower column 456, a telescoping index 458, and an adaptor cap 454.Bubble vials 460 are provided, coupled to the adaptor cap 454. Theweight 452 is sized to fit into the cavity of the post sleeve and reston the bottom, and the adaptor cap 454 is sized to fit snugly into theopening and hold the index 458 in alignment with the cavity.

It will be recognized that, because of cavities within the post sleeve,including the main cavity 462, the sleeve will float in freshly pouredconcrete. The weight provides sufficient ballast to allow the sleeve tomaintain a vertical position in the wet concrete without externalsupport. The installer pours the concrete into an empty post hole, thenimmediately lowers the sleeve 206 and positioning device into theslurry. Using the bubble vials, the installer plumbs the post sleeve 206by simply grasping the index 458 and moving it until the bubbles arecentered in both axes. After installing a second post sleeve, theinstaller uses a tape measure to measure the distance, on a horizontalline, from one sleeve or index to the next. Using a hand-held laserlevel, positioned on the top of the post sleeve 206 or index 458, theinstaller marks the position of one post sleeve on the index of anadjoining sleeve to determine the relative elevation.

If the sleeve 206 needs to be deeper in the footing, the installer addsweight to the ballast so the sleeve will settle. For example, theinstaller can simply pour water into the sleeve until it settles to thedesired depth. In the sleeve 206 that is pictured in FIG. 13, atemporary degradable seal 464 is provided to form a percolation chamber466 at the bottom of the sleeve, to eventually permit water to percolateinto a porous footing. The seal 464 is made from a material configuredto disintegrate and, preferably, dissolve in water, but even with waterin the chamber the seal will last long enough for the footing to set.

Using a laser plane projector to establish a vertical plane along afence line, the index 458 of the positioning device 450 can be alignedwith the projected vertical line. By starting at the farthest hole andworking toward the projector, the index of one post sleeve will notinterfere with the reference plane while installing the next postsleeve. Provided the total change in elevation of the fence line doesnot exceed the capacity of the index 458, a horizontal plane can also beprojected from the highest point along the fence line, to establishchanges in elevation relative to the projector. The installer notes theheight at which the index 458 intersects the plane, and by subtractingthe value noted on an adjoining index, determines the relative elevationof the respective post sleeves. In the event the total change is inexcess of the capacity of the index 458, a more localized reading, fromone sleeve to the next, can be obtained by using a laser level, asdescribed above.

According to an embodiment, a battery-powered vibrator is attached to orencased by the weight 452 to remove unwanted air from the concretefooting and assist in self plumbing.

According to another embodiment, a compass is provided, coupled to theindex 458 or adaptor cap 460 to assist the installer in properlyorienting the post sleeve.

According to another embodiment, a bullseye level is coupled to thetop-most surface of the index 458 to provide a convenient referencewhile a user plumbs the post sleeve.

It will be recognized that the post sleeve positioning device 450 is notideally suited to position post sleeves as precisely as are the spiderframes disclosed above. However, it is envisioned that such a devicewill be useful to consumers who prefer to do much of the workthemselves, and do not have a need sufficient to justify the greatercost of buying or renting a number of spider frames to install arelatively small number of post sleeves.

According to another embodiment, a post sleeve positioning devicecomprises a tripod, configured to be positioned over a post hole and tosupport a post sleeve hanging thereunder. By changing the length of oneor two of the legs, the position of the post sleeve can be adjusted inthe X and Y axes, and the elevation of the post sleeve can be adjustedby making equal changes to all of the legs. Other structures forcontrolling position and orientation of a post sleeve coupled to thetripod are also within the abilities of one of ordinary skill in theart.

FIG. 14 shows a ground scanner system 470 according to one embodiment.The system 470 includes a support post 472 that is rotatably coupled toa sleeve insert positioned in a first post sleeve 206 a. A referencepost 474 is rotatably coupled to a sleeve insert positioned in a secondpost sleeve 206 b, and includes spaced-apart arms 476 extendingvertically from the reference post. A cross beam 478 is pivotablycoupled to the support beam 472 by a bracket 484, and extendshorizontally toward the second post sleeve 206 b, to be received betweenthe spaced-apart arms 476.

The user adjusts the height of the cross beam 478 where it passesbetween the arms 476 until the cross beam is level, as indicated by abubble vial 480 attached to the cross beam or by some other knownmethod. A ground scanner 482 is moved along a track extending along thebottom of the cross beam 478. As it is moved, using known rangefindingtechnology, the ground scanner 482 maps the surface of the grounddirectly beneath the cross beam 478, along the line that a fence panelwill eventually occupy. With this data, the manufacturer can fabricate afence panel with a bottom edge that exactly follows the contour of theground between the post sleeves 206 a and 206 b, including anyobstructions, such as boulders, curbs, etc.

The position of the bracket 484 on the support post 472 can be adjustedvertically, to accommodate obstacles or extreme differences inelevation. The support post 472 and the reference post 474 can berotated around their Z axes, relative to their respective sleeveinserts, so that they can accommodate post sleeves that are notrotationally aligned with each other.

According to an embodiment, the various elements of the ground scannersystem 470 are provided with the necessary graduated scales or sensorsto obtain relative distance, elevation, and orientation data withrespect to the placement of post sleeves 206 a and 206 b. Such scales orsensors are within the abilities of one of ordinary skill, especially inview of the other embodiments disclosed herein. For example, the crossbeam 478 can be provided with distance markings along its length, and areference point on one or both of the arms 476 of the reference post474, and from which the precise distance between the sleeves can beobtained. Likewise, scales can be provided that display the angles ofthe support post 472 and the reference post 474 relative to theirrespective sleeve inserts, and the height of the cross beam 478 aboveeach sleeve. Of course, the system can also be configured to obtain thesame information more or less automatically, using electronic sensors,transmitters, receivers, etc.

A method is provided, according to an embodiment, by which an installerfirst prepares post holes and installs post sleeves, correctlypositioned to within a substantial tolerance. This can be done, forexample, using GPS technology, by floating the sleeves, as describedwith reference to FIG. 13, or by more conventional methods. Theinstaller (or another individual) then moves along the line of postsleeves and collects the data necessary to manufacture the posts andpanels, using, for example, a system similar to that described withreference to FIG. 14. This can be done immediately after the sleeves areinstalled, or any time thereafter.

Various devices and methods have been described for obtaining dataregarding the relative positions of post sleeves, including elevation,orientation, and distance. It should be noted that in some cases, theonly information necessary is distance and elevation, or even distance,alone. For example, if a fence is to include only straight lines andright angles, and the posts are to be square and aligned with the fenceline, every fence panel will be perpendicular to the faces of the poststo which it is attached. Thus, orientation of each post need not bemeasured. This is also true if the posts are to be round, regardless ofthe path followed by the fence line. Likewise, if the fence is to followa substantially level line, elevation need not be measured.

Thus, while various embodiments enable the collection and transmissionof many classes of data, the scope of the claims also encompassesembodiments in which only limited data is collected or transmitted.

Many of the disclosed embodiments can be adapted for use with other postsupport mechanisms, such as, for example, post brackets, which aresometimes used to attach posts to existing surfaces. Furthermore, evenin cases where posts are set in the ground by conventional means,without sleeves, custom fence panels can be manufactured as disclosed,if the necessary data is collected and transmitted to the manufacturer.

According to various embodiments, as discussed above, data related tothe positioning of the post sleeves of a fence are collected for use bya fabricator to make fence panels or kits in a factory environment thatare “custom made” for that fence. According to another embodiment, acentral data archive is provided, to which the data is also sent. Bycollecting and storing such information, it is preserved for access atany time in the future. For example, if a portion of a fence is damaged,the information is available to produce replacement panels with the samestyle, material, and finish as the original fence, even if the fence isa one-of-a-kind design. Any properly equipped fabricator can use thepreviously stored data to manufacture replacement panels that willperfectly match the original design. Furthermore, when a fence is to becompletely replaced, it is not necessary to obtain new data unless thelocation of the fence also changes. Otherwise, new posts can be placedin the original post sleeves, meaning that the original data will stillbe valid.

Ideally, the central archive collects data from a very largegeographical region, e.g., nationally. However, a number of differentfacilities can collect the information for respective smallergeographical areas, as well, such as by state or county. Archives can bemaintained by any of a number of different entities, including, forexample, local or national trade groups, for-profit companies, localgovernments or extension services, fabricators themselves, etc.

Nevertheless, there are some benefits that are obtained from centralizedcollection of the information. For example, statistical data can beobtained for evaluation of performance and durability of different postsleeve designs, materials, and installation methods, over extendedperiods, in many different environments. Also, with many archives, itmay be at times difficult to locate data for a given fence. Controllingentities can move or go out of business or consolidate; competingmanufacturers could be reluctant to share data, etc. In contrast, ifthere is one central archive, there is never a problem locating thedata, and it is more likely to remain current.

According to one embodiment, a fence installation process is provided.Initially, a piece of property is surveyed and the property lines aredefined. This can be in conjunction with the subdivision of a largerparcel, or by a developer who surveys all the lots of a housingdevelopment, etc. The locations of post sleeves are then determined.According to one embodiment, a software program is provided that isconfigured to automatically select the positions and spacing of the postsleeves on the basis of the plot plan or survey data, and preferencesentered by a user. For example, the user can define the maximum distancebetween posts or the maximum length of fence rails, and can select thelocations of gates, runs, etc., which are shown on a site map that canbe printed out for use by the installer. If the post sleeve installationsystem is configured to employ a post-to-post spacing format, like thatdescribed with reference to FIGS. 2-8, the locations of the fence andmain posts are marked on the property by referring to the site map. Themarkings are general in nature, e.g., a string line, laser line, stakes,GPS etc., to assist in initial positioning of the post holes and mainpost sleeves. The post holes are then dug and the sleeves are installed.Although the installer works from the site map and spacing previouslyset forth, the actual position and orientation of each post sleeve,relative to the adjacent sleeves, is determined and recorded by theinstaller. This ensures that small deviations from the prescribedpositioning are recorded, so the fence panels will fit properly.

If the installation system is configured to employ a primary referencepoint, e.g., the prism system described with reference to FIGS. 10 and11, then the reference point where the surveyor device is positioned isselected when the sleeve positions are determined and marked on theproperty. The installer then digs the post holes and installs thesleeves, positioned with reference to the locator unit as describedabove.

If the installation system is configured to employ a GPS positioningsystem, such as that described with reference to FIG. 11, the precisecoordinates of each post are determined and shown on the site map, andthe installer works from the site map to dig the holes and install thepost sleeves, which obviates the need to mark the property.

Alternatively, an installer merely marks the location of the fence andmain posts of a fence run using existing landmarks as references, thencalculates an appropriate equal spacing for the remaining posts of therun.

Regardless of the system employed to position and install the sleeves,in each case, the positions of each sleeve, relative to the adjacentsleeves, is obtained and recorded, because this is what the fabricatorwill need to produce the fence panels.

The post sleeves may be installed before other construction is begun,and perhaps even before the property is fully graded. The installerpositions the post sleeves at the finish elevation, even if the groundwhere the post sleeves are installed is not yet at the finish gradelevel. In such a case, the contractor may thereafter use thepre-positioned post sleeves as markers when finish grading the property.This means that particular sleeves may be installed some distance aboveor below the current grade. To install below grade, of course, theinstaller merely digs a deeper post hole and places the sleeve at thecorrect level. To install more than a few inches above grade, theinstaller can use a commercially available concrete form (e.g., aSonotube® form) to make a short column in which the sleeve is embedded.The sleeves can be capped to prevent dirt from falling inside, or markerflags can be placed in the sleeves so the graders can see them, forreference, and to avoid damaging them. The sleeves are positioned sothat, when the property is at the finish grade, the sleeves (capped) area few inches below the surface, and may even be covered with sod.

During installation of the post sleeves, information necessary formanufacture of the panels is collected, either automatically ormanually, depending on the installation system used. This information issent to a central archive, where it is assigned a file number andstored. The information provided by the post sleeve installer includesthe locations of all of the post sleeves on the property, their relativepositions and orientations, and the UI of each sleeve. Additionalinformation that can be provided includes, for example, the sleeve modeland manufacturer, the grade of concrete used to install the sleeve,provisions made for drainage, depth of concrete, hole diameter, and GPScoordinates. Also the installation date, the installing contractor, andthe current property owner.

When a property owner (or contractor or developer) is ready to install afence, the style, material, and finish of the fence is selected. Theowner provides a fabricator with the file number of the archived data,and the details of the selected design. The fabricator then obtains thedata from the central archive, and also provides the archive withadditional information, including the material and design of the fence,and the manufacture and projected installation dates. The fabricatormanufactures and marks the fence components in the selected design andaccording to the data obtained from the archive, and ships them to thelocation of the property.

An installer uncovers the tops of the sleeves, and places the posts inthe corresponding sleeves, then attaches each panel to the appropriateposts, referring to the markings placed by the manufacturer on the fencecomponents and the UI of each post sleeve to correctly position eachpost and panel. The fence components can be installed by a contractorworking for the developer or property owner, or a reasonably handyproperty owner can do the installation, unassisted.

In cases where the fence is installed by a developer when the propertyis first subdivided and developed, installation may be days, weeks, ormonths after installation of the post sleeves. The developer may installfence panels only along property lines around the perimeter of adevelopment, while leaving the remaining post sleeves unoccupied. Iffences are not installed by the developer, some who later purchase lotsmay elect to install fences, while others may not. However, even yearslater, a second or third owner can choose to install a fence, and thesleeves will be waiting and the data still available at the archive.Furthermore, because the sleeves are installed according to the originalsurvey when the property is subdivided, they will appear on later surveymaps and in the legal description of the property, and can be used asreference markers to correctly define boundaries thereafter. Thus,installing the post sleeves can enhance the value of the property,regardless of whether a fence is actually installed at that time.

When an individual purchases a lot, the data is already on file, and theowner can consult with a contractor, a fabricator, or refer tomanufacturers' web sites to select a fence design, materials, finish,etc. The user can provide a file number or other information to identifythe specific property, and the consultant or website software can thendownload the pertinent data from the central archive and produce arendering of the property, showing a fence in the selected design, orshowing various options for the user to choose from. Once the user hasmade a selection, the order can be placed immediately, by anyappropriate means, including by telephone, email, web order, etc.

When a customer orders the panels for a fence, the fabricator enters thenecessary data into its optimization system. If the fence style is oneof a number of designs that are offered as standard by the fabricator,information specific to that style can be already present in the system,so that when an operator enters the information specific to the postsleeves of the customer's property, the system automatically calculatesthe numbers and dimensions of all the individual parts of each panel tobe manufactured.

At any given time, the fabricator may have dozens of fence orders inqueue. Lumber enters the system in random length boards according to thelengths of the stems from which they were milled, or as mill shorts. Thesystem carries a running list of material yet to be cut for all thepending orders. As each board is fed into the machinery, the systemscans it to determine its dimensions and to detect flaws, thencalculates which of the list of pieces can be cut from the board toresult in the least amount of waste, cutting the board accordingly. Thesystem can also be configured to consider the structural strengthnecessary for a given piece. Thus, for example, a rail that willeventually span between two posts and support much of the weight of thepanel, as well as wind load, etc., may need to be substantially clear ofknots and checks, while a slat of a lattice, which will never berequired to support more than a minimal load, can have a number ofstructural flaws, provided they don't detract from its appearance.

After cutting, each piece is marked with a code that indicates the job,panel, and component, and is then sorted, at least by job. Marking canbe by any of a number of known means, including stamping, laser, spray,etc. One of the fence rails of each panel is also marked at each endwith the UI of the respective post sleeves between which that panel isto be installed. During installation, the installer will refer to thismarking to determine the location of the particular panel. If necessary,the marked portions can be covered by a clear wax or finish to preventstain or paint that is later applied from obscuring the markings.

According to one embodiment, assembly workers assemble all thecomponents of each panel, referring to the markings to correctlyassemble the components. The markings can be in a computer-readableformat, such as bar codes, so that if a worker is unsure of where aparticular piece of material belongs, its marking can be passed under areader, and the system will indicate the panel and location of thepiece. According to another embodiment, the system automaticallyassembles at least portions of some or all of the panels, with workersdoing final assembly.

Following assembly, the components of the fence are finished, by dippingor spraying each component with a stain or paint finish selected by thecustomer. Once the finish has cured, the components are crated or bandedfor shipment. The panels are preferably stacked and banded in order ofposition in the finished fence, so that the installer can place a stackof panels on a cart or flatbed truck and, moving along the fence line,drop the correct panel at each position, in order. In most cases, therewill be little or no waste at the fence site, apart from packingmaterial, which itself will be minimal.

Over time, fence posts and panels will be damaged or will deteriorate.Replacement panels can be easily obtained. Either the property owner orthe manufacturer can obtain the data from the repository, includingstyle, material, and finish. The customer merely indicates which panelsand which posts need to be replaced, and the manufacturer can produce anidentical panel from the original data, which is then shipped to thecustomer. If posts need to be replaced, the old posts are pulled fromthe sleeves, which are then cleaned, if necessary, and the new posts aredropped in. The panels are then installed as previously described.

While fabrication of wood panels is described above, other materials,such as plastics and metal, can also be processed similarly. This isespecially true where, because of normal operations in related orunrelated industries, there is a surplus of materials that are normallyscrapped, but that could be used in fence panels.

According to an embodiment, the end consumer accesses a software programthat provides all the necessary tools to select a fence design and placean order. The program may be accessed, for example, via the internet, ata retail location, or with the assistance of a contractor. The user caninput an address or some other identifier such as tax lot number etc. Ifdata related to that property is present in the central repository or inother accessible records, the program then populates with a 2 or 3dimensional rendering of the property, according to the information anddetail that is available. The rendering includes the current fence orpreviously installed post sleeves. The user selects materials, color andfinish, style, and other details, all of which are displayed anddescribed in the rendering, as they are selected. Information aboutmanufacturers is provided, such as delivery times and prices. A runningsubtotal of the cost of the fence is provided, together with costs (orestimates) of delivery, installation, and tax, together with a totalcost. The user is thus able to select and order a fence according topersonal criteria, without outside assistance or interference, orwhatever level of assistance or advice is desired. Once an order isplaced, the system updates the central repository accordingly.

In a similar fashion, a user can select and order an individualreplacement panel, inputting the UI or identifying the particular panelfrom the 3D model. Additionally, the consumer can log on to the website,or otherwise access the system from time to time, to update the databaseto reflect changes, e.g., new stain colors, contractors used, etc., orto access the actual plot plan for future reference.

While devices configured for use in installing post sleeves may berecited in the claims, unless specifically recited as an element, postsleeve is not to be read as a claim limitation, i.e., if a claim readson a device with a post sleeve attached, it will also read on the samedevice without the post sleeve.

References in the specification and claims to movement in or parallel toordinal axes, such as the X, Y, or Z axis, do not refer to specificaxes, but to three mutually orthogonal axes, except that reference tothe Z axis can be understood as referring in particular to a verticalaxis, while X and Y axes can be understood as lying in a horizontalplane. Reference to orientation is to be understood as referring to anangle of rotation around a vertical axis.

The term position refers to the location of an element in threeorthogonal axes, unless explicitly limited further.

The term post is used in the specification and claims in relation to avertical support member, such as is used, for example, to support afence or sign, and is not to be construed as meaning subsequent to.

The term post bracket is used as a generic term to refer to hardwareconfigured to support a post at or above a surface, including, forexample, a bolt pattern plate, a “U” bracket, a pier bracket, and a postbracket. The term post receiver is used in the claims to refergenerically to structures configured to receive and support a post,including, for example, prefabricated post sleeves, post brackets, andpoured-in-place post sleeves (made using a post hole mold).

Adjustments made before coupling the post sleeve to a device can be readas adjusting the post sleeve. The abstract of the present disclosure isprovided as a brief outline of some of the principles of the inventionaccording to one embodiment, and is not intended as a complete ordefinitive description of any embodiment thereof, nor should it berelied upon to define terms used in the specification or claims. Theabstract does not limit the scope of the claims.

Elements of the various embodiments described above can be combined, andfurther modifications can be made, to provide further embodimentswithout deviating from the spirit and scope of the invention. All of theU.S. patents, U.S. patent application publications, U.S. patentapplications, foreign patents, foreign patent applications andnon-patent publications referred to in this specification and/or listedin the Application Data Sheet, are incorporated herein by reference, intheir entirety. Aspects of the embodiments can be modified, if necessaryto employ concepts of the various patents, applications and publicationsto provide yet further embodiments.

These and other changes can be made to the embodiments in light of theabove-detailed description. In general, in the following claims, theterms used should not be construed to limit the claims to the specificembodiments disclosed in the specification, but should be construed toinclude all possible embodiments along with the full scope ofequivalents to which such claims are entitled. Accordingly, the claimsare not limited by the disclosure.

1. A post positioning device, comprising: a positioning element sized tobe received into a cavity of a post sleeve; an index coupled to thepositioning element so as to extend from an opening of the cavity whilethe positioning element is received in the cavity, the index having agraduated scale extending along a portion of its length, and thepositioning element being configured to support the index in alignmentwith a longitudinal axis of the cavity.
 2. The device of claim 1 whereinthe positioning element is a first positioning element, configured to bereceived in a lower end of the cavity, the device further comprising asecond positioning element configured to be received at least partiallywithin the opening of the cavity, the first and second positioningelements together configured to support the index in alignment with alongitudinal axis of the cavity.
 3. The device of claim 2, comprising asupport column coupled at a first end to the first positioning elementand configured to be supported at a second end by the second positioningelement, the index being positioned within the support column andconfigured to telescope therefrom to extend from the opening of thecavity.
 4. The device of claim 1 wherein the positioning elementincludes a weight configured to act as ballast to assist in verticalalignment of the post sleeve during installation.
 5. The device of claim1 wherein the positioning element includes a vibrator configured toassist in removal of air from concrete poured as a footing around thepost sleeve during installation.
 6. The device of claim 2 wherein thesecond positioning element includes an adaptor cap configured to fitsnugly into the opening of the cavity.
 7. A device comprising: a crossbeam having first and second ends; a first support structure configuredto support the first end of the cross beam in a position correspondingto a location of a first post of a fence; a second support structureconfigured to support the second end of the cross beam in a positioncorresponding to a location of a second post of the fence; a groundscanner coupled to the cross beam and configured to determined a contourof a ground surface extending along a line between the first and secondsupport structures.
 8. The device of claim 7 wherein the crossbeamcomprises a track extending longitudinally on the cross beam, andwherein the ground scanner is configured to travel along the track ofthe cross beam, and to detect a value corresponding to a distance fromthe ground scanner to the ground surface.
 9. The device of claim 7wherein the cross beam is pivotably coupled to the first supportstructure, and the second support is configured to receive the crossbeam at any vertical position within a range of vertical positions, suchthat the cross beam can be positioned to extend horizontally between thefirst and second support structures while relative elevations of thelocations of the first and second posts of the fence are within a rangecorresponding to the range of vertical positions.
 10. The device ofclaim 9 wherein the second support structure includes means fordetermining a difference in relative elevations of the locations of thefirst and second posts of the fence on the basis of a vertical positionat which the cross beam is received.
 11. The device of claim 7comprising means for determining a distance between the locations of thefirst and second posts of the fence.
 12. The device of claim 7comprising means for determining relative orientations of the first andsecond posts of the fence.
 13. The device of claim 7 wherein the firstsupport structure comprises: a sleeve insert configured to be receivedin a first post sleeve positioned at the location of the first post ofthe fence; a support post coupled to the sleeve insert so as to extendfrom the sleeve insert in alignment with the first post sleeve, and soas to be rotatable around a longitudinal axis of the first post sleeve;and a bracket coupled to the support post and configured to receive thefirst end of the cross beam.
 14. The device of claim 13 wherein: thefirst support structure includes a scale positioned and calibrated todisplay a value corresponding to an orientation of the first post sleeverelative to the cross beam; and the cross beam includes a scalepositioned and calibrated to display a value corresponding to a distancefrom the first post sleeve to the second post sleeve.
 15. The device ofclaim 13 wherein the second support structure comprises: a sleeve insertconfigured to be received in a second post sleeve positioned at thelocation of the second post of the fence; a reference post coupled tothe sleeve insert so as to extend from the sleeve insert in alignmentwith the second post sleeve, and so as to be rotatable around alongitudinal axis of the second post sleeve; and first and second armscoupled to the reference post and spaced apart a distance sufficient toreceive the second end of the cross beam therebetween.
 16. The device ofclaim 15 wherein the second support structure includes scales positionedand calibrated to display a value corresponding to an orientation of thesecond post sleeve relative to the cross beam, and a value correspondingto a vertical position of the cross beam relative to the second postsleeve.
 17. A method, comprising: positioning a quantity of uncuredconcrete in a posthole; positioning a post positioning device into acavity of a premanufactured post sleeve the post positioning deviceconfigured to receive an index; positioning an index in the postpositioning device such that the index extends from an opening of thecavity, aligned with a longitudinal axis of the cavity; positioning thepost sleeve in the posthole so that the post sleeve floats in thequantity of uncured concrete; before the uncured concrete hardens,adjusting a position of the post sleeve in the posthole to plumb theindex; and removing the index from the posthole.
 18. The method of claim17, comprising, prior to removing the index, determining a distancebetween the index and an additional index extending from an opening ofan additional post sleeve.
 19. The method of claim 17, comprising, priorto removing the index, determining an elevation of the post sleeverelative to an additional post sleeve on the basis of a vertical scalepositioned along a portion of the index.
 20. The method of claim 17wherein the adjusting a position comprises adjusting an orientation ofthe post sleeve in the posthole.
 21. A method, comprising: supporting afirst end of a cross beam in a position corresponding to a location of afirst post of a fence; supporting a second end of the cross beam in aposition corresponding to a location of a second post of the fence, atan elevation that is equal to an elevation of the first end of the crossbeam; and mapping a ground surface relative to the cross beam along aline between the locations of the first and second posts of the fence.22. The method of claim 21 wherein the mapping a ground surfacecomprises moving a ground scanner along a track of the cross beam anddetecting changes in elevation of the ground surface along the line. 23.The method of claim 21 wherein: the supporting a first end comprises:placing a sleeve insert of a first support structure in a first postsleeve that is positioned at the location of the first post of thefence, and coupling the first end of the cross beam to a support post ofthe first support structure; and the supporting a second end comprises:placing a sleeve insert of a second support structure in a second postsleeve that is positioned at the location of the second post of thefence, adjusting an elevation of the second end of the cross beam toplace the second end at the elevation that is equal to the elevation ofthe first end, and coupling the second end of the cross beam to areference post of the second support structure.